kick start shaft

[dANbOT]

I've been snapping kick start shafts on my 2014 300.
The original snapped a while back, so I replaced it with an eBay shaft out of a 2013 which lasted a little while before snapping in the same spot. I had one of them welded up at a local shop and was hopeful I had a permanent solution, but it let go yesterday as well. They are going to try again to weld both shafts.

I see more shafts on ebay, but it seems like wasted money if they are just going to snap.
I'm not violently kicking the lever, in fact I'm recovering from knee surgery done last fall so my leg is pretty weak in kicking force. I've also been cautious kicking it since this started happening. E start problems are also haunting me so I'm left with no way to start my bike and can't enjoy my otherwise AWESOME bike. Is nobody else having this problem?

Does anyone know if there is a crossover kickstart mechanism? I thought maybe since the YZ kick levers fit on the shaft, maybe the whole mechanism is a basic copy?

[dANbOT]

On the right is the original shaft, on the left is the 2013 shaft after the weld job failed.

[Zman]

Does it kick smoothly? Is it possible that your timing is too far advanced and it is kicking back? I think it would be difficult to weld that and retain the strength. I probably have a good shaft from a 2004 I could sell you for a reasonable price.

[dANbOT]

I'm digging through ebay looking for parts, and saw these older kick start assembly's. This pic is from an ad for a 2000 ec250 unit.
I can see the shaft is more robust in the area mine have snapped at. Another ad for an 02 assembly had the same tougher looking shaft end.


Overall, the unit looks similar. Both have 28 tooth gears, and look like similar dimensions except for the design of the outer end of the shaft, and the steel notched collar instead of plastic on the newer ones.
I feel like I might have found a solution if these older units / shafts fit in my 14. I'll have to take a gamble and order one I guess.

Can anyone confirm that the 2000 - 2004 generation GG's are the same story of matching to the YZ250 kick levers?

Hard to believe I'm the only one snapping these!

[dANbOT]

Originally Posted by Zman

Does it kick smoothly? Is it possible that your timing is too far advanced and it is kicking back? I think it would be difficult to weld that and retain the strength. I probably have a good shaft from a 2004 I could sell you for a reasonable price.

Yeah it kicks smoothly, Ive never noticed a drastic kick back. I could look at the timing plate and see if it has moved or looks odd, but Ive never touched it.
I'm thinking an older style shaft, or complete assembly will be the ticket if one fits.

[dANbOT]

Welders just called. They spent 2 hours notching and welding the two shafts. I'll install one, and hope it keeps me riding until I get a replacement!

Your theory of kick back has me thinking now... maybe a source of my e start problems too? Have to look into it. Bike is full stock aside from main and pilot at 3000 - 7500' though... wouldn't expect det.

[dANbOT]

Update

My bike was down for a couple weeks, got her back running. While it was down, I received two eBay kick assemblies... one from a 2000 EC, the other from a 2002.
I started riding the bike with one of the welded shafts in place, but it was slowly starting to bend. I replaced it with the 2002 complete kick start assembly (fit perfect!). The shafts on either of these older assemblies is thicker in the location that my newer shafts have been breaking. I'm hopeful I will have no further issues.

[Zman]

Good to hear and congrats!

[3beejay3]

Much of the GasGas two stroke engine is based on the Honda CR 250R engine from back in the day. I wonder if a Honda part will work?

[dANbOT]

I thought about that, since I have a CR250 in my garage.
I can say for sure that the external splines are completely different, and my CR kick lever will not go on the GG shaft. I considered tearing the side cover off the CR to see if it matched internally, but never did.